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Page 1 P E R F O R M a N C E E N G I N E PERFORMANCE ENGINE COMPONENTS A History Of Excellence Since it was formed in 1958 by Mike Costin and the late Keith Duckworth in a small workshop in Acton, England, Cosworth has become the most successful engine manufacturer in the history of Formula One. In addition it has achieved enormous success in IndyCars, Champ Cars, rallying, sports cars and touring cars. The company soon outgrew its little workshop in Acton and moved to north London, where the Ford 105E engine was developed. Cosworth’s first race win followed – at Goodwood in 1960, a Formula Junior win for the young Jim Clark. By the mid 1960s the company had moved again, to Northampton, and in 1966 a contract was signed with Ford to develop a new three-litre Formula One engine. The legendary DFV was born. Jim Clark again provided the maiden victory, first time out at the Dutch Grand Prix in 1967. The DFV went on to dominate F1 for 15 years with 155 race wins. In the 1970s the Cosworth DFX ruled the US Indycar scene with an incredible 151 race wins in a 14-year reign, including 10 driver’s championships and 10 Indianapolis 500 victories. Through the 1980s and ‘90s, Cosworth continued to provide race-winning power with three World Touring Car titles in 1987, ‘93 and ‘94. In Formula 1 the HB engine won 11 races, while in the US Nigel Mansell’s CART championship in 1993 and Jacques Villeneuve’s in 1995 were both powered by Cosworth XBs. In 1994 the Zetec V8 F1 engine took Michael Schumacher to his first world driver’s title. In rallying the Ford Escort Cosworth and the Duratec-R powered Focus WRC gave Ford yet more success. In 2004 Cosworth still provided the power to 30% of the F1 grid, as well as to the entire Champ Car World Series and the Ford Focus WRC cars. In 2005 Cosworth powered Red Bull’s impressive debut F1 season. In 2006, Cosworth powered the Williams F1 car with a brand new V8 engine which was later acknowledged as the most powerful and highest revving engine on the 2006 grid. Today, Cosworth continues to enjoy racing success in leading American open wheel series such as Champ Car and Formula Atlantic. The engineering expertise gained over the last 5 decades have enabled Cosworth to launch a broad array of high performance engine components for the aftermarket. With the product range increasing on a continual basis, Cosworth power is now accessible to everyone. A History Of Excellence Contents Big Valve Cylinder Heads 5 High Performance Short Block Assemblies 7 High Performance Long Block Assemblies 8 Billet Crankshafts 9 Stroker Engine Kits 9 Forged Connecting Rods 10 Ultra High Performance Engine Bearings 11 Forged Pistons 12 Performance Ring Sets 13 High Performance Camshafts 15 High Performance Head Gaskets 17 Oil Control / Miscellaneous 18 Ultra High Performance Head Studs 20 High Performance Valve Train 20 Induction / Fuel 22 Disclaimer 23 3 Big Valve Cylinder Heads For over 40 years, Cosworth has offer superior performance for your Each original cylinder head design been the leader in innovative multi high performance engine. is carefully evaluated and tested to valve cylinder head design for establish the improvements required both racing and high performance to meet the target performance level. production cars. The Cosworth CNC Hours of testing and flow bench Ported Big Valve Cylinder head range validation are used to determine is the latest advancement. Modified the best advanced port design from new OE cylinder head castings, yielding maximum usable power substantial gas flow improvements and response. However, there is and upgraded valve train components more to cylinder head design than Nissan VQ35DE just maximum flow. It is critical that port velocity is maintained CNC Ported Big Valve Cylinder Heads to ensure drivability and valve Part No. Application Specification train components are matched to KK3670 Subaru WRX STI EJ25 (2.5L) Pair 2004-2006 guarantee reliable performance. KK3671 Nissan VQ35 (3.5L) Pair 2002-2005 KK3918 Nissan VQ35 (3.5L) Pair 2006 “Rev Up” version Once all of these factors have KK3672 Mitsubishi Evo VII-VIII 4G63 (2.0L) 2000-2005 been tested and validated, the final KK3852 Mitsubishi Evo IX 4G63 (2.0L) 2006 MIVEC port contour is digitized. Using the KK3673 BMW MINI Cooper/Cooper S (1.6L) digitized program, we then reshape 20001699 Subaru WRX STI EJ25 (2.5L) Pair 2007 both intake and exhaust ports 20000691 Ford Duratec, 2.0L/2.3L using a 5 axis CNC mill producing 20000704 Mazda MZR, 2.0L/2.3L an accurate and consistent port shape every time. In addition to re- CNC Ported Big Valve Cylinder Heads with Camshafts shaping and enlarging the intake Part No. Application Specification and exhaust ports, most Big Valve Pair with KK3766 Camshafts and valve lash set Cylinder heads feature a re-shaped SB8010 Subaru WRX STI EJ25 (2.5L) with cam bucket (USA) combustion chamber to un-shroud Pair with KK3920 Camshafts and valve lash set SB8012 Subaru WRX STI EJ25 (2.5L) with cam bucket (Japan/Euro) the valves increasing air flow and 20002024 Subaru WRX STI EJ25 (2.5L) Pair 2007 with KK3766 Camshafts (USA) performance. After machining, each 20002026 Subaru WRX STI EJ25 (2.5L) Pair 2007 with KK3920 Camshafts (Japan/Euro) cylinder head receives a multi- angle high performance valve job on our precision CNC valve seat cutter. Then each cylinder head is ultrasonically cleaned, serialized and finally hand assembled with select high performance valve train components, ready to install on your engine. Mitsubishi 4G63 Subaru EJ25 4 Big Valve Cylinder Heads Key Features: All new OE Castings Enlarged intake and exhaust ports Large diameter stainless steel intake valves Large diameter inconel exhaust valves Hi-rev, dual valve springs Titanium retainers Hardened steel spring platforms Reshaped combustion chamber on most applications Flow bench proven design Dynamometer tested Machined Cosworth logo Precision multi-angle valve job Pre-assembled, ready to install Machined port bore finish Knife edge port divider Cylinder head development CNC Valve seat cutter 5 High Performance Short Block Assemblies Cosworth high performance engine forged crankshaft or Cosworth billet assemblies are the perfect basis for crank along with Cosworth forged your high performance application. connecting rods, Cosworth tri-metal Each version has gone through bearings and Cosworth forged countless hours of engineering pistons. The motorsport grade parts and evaluation to determine the are then professionally assembled best combination of parts and build by expert engine builders in the specification, ensuring maximum Cosworth engine assembly facility. reliable performance. Each Each high performance engine Cosworth high performance engine assembly includes a complete assembly starts with all new select specification sheet listing all critical components as the foundation of dimensions along with a serialized the performance build. Every block plaque. For maximum performance, is thoroughly inspected before the combine with a Cosworth CNC cylinders are honed to perfection. We ported Big Valve Cylinder Head and then balance the rotating assembly camshaft set. that includes either a new factory High Performance Short Blocks Part No. Application Specification SB8005 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods SB8007 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods with 79mm Billet Crank 20000067 Nissan VQ35 Short Block (3.5L) Lo comp 8.8:1 KK3879 Nissan VQ35 Short Block (3.5L) Hi comp 11:1 Mitsubishi Evo VIII/IX 4G63 Short Block CI8015 Forged Pistons, Rods (2.0L) Mitsubishi Evo VII/IX 4G63 Short Block CI8018 Forged Pistons, Rods with 94mm Billet Crank (2.2L) Subaru EJ25 High Performance Short Block 2.5L The Cosworth EJ25 is an excellent starting point for high performance and track day applications. New Subaru EJ25 STI EJ257 Cosworth Tri-metal bearings Block Balanced to within 0.5 gram New Subaru EJ25 STI Forged Complete blue-printed assembly Crankshaft or Cosworth Billet Ring gap set Crank (79mm) Bearing clearance checked Cosworth Forged H-beam Deck height checked connecting rods Connecting Rod side clearance Cosworth Forged Pistons checked (99.5mm) and rings Crankshaft end float checked 6 High Performance Short Block Assemblies Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L The Cosworth 2.0L 4G63 is an excellent starting point for high performance and track day applications. New Mitsubishi 4G63 Evolution Piston squirt jets Block Balanced to within 0.5 gram New Mitsubishi forged crankshaft Complete blue-printed assembly (88mm) Ring gap set Cosworth Forged H-beam Bearing clearance checked connecting rods Deck height checked Cosworth Forged Pistons Connecting Rod side clearance (85mm) and rings checked Cosworth Tri-metal bearings Crankshaft end float checked Cosworth Heavy Duty main studs Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.2L The Cosworth 4G63 2.2L stroker engine combines the perfect bore to stroke ratio, yielding potentially big gains in torque while still allowing the engine to rotate and produce power at higher RPMs. New Mitsubishi 4G63 Evolution Piston squirt jets High Performance Short Blocks Block Balanced to within 0.5 gram Part No. Application Specification New Cosworth Billet Crank Complete blue-printed assembly SB8005 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods (94mm) Ring gap set SB8007 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods with 79mm Billet Crank Cosworth Forged H-beam Bearing clearance checked 20000067 Nissan VQ35 Short Block (3.5L) Lo comp 8.8:1 connecting rods Deck height checked Cosworth Forged Pistons Connecting Rod side clearance KK3879 Nissan VQ35 Short Block (3.5L) Hi comp 11:1 Mitsubishi Evo VIII/IX 4G63 Short Block (86mm) and rings checked CI8015 Forged Pistons, Rods (2.0L) Cosworth Tri-metal bearings Crankshaft end float checked Mitsubishi Evo VII/IX 4G63 Short Block CI8018 Forged Pistons, Rods with 94mm Billet Crank Cosworth Heavy Duty main studs (2.2L) Nissan VQ35DE (350Z-G35) High Performance Short Block 3.5L The Cosworth VQ35DE high performance short block is the perfect foundation for your high performance application.
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